System and method for optical measurements in a rotary machine

ABSTRACT

A system is provided with a measurement system having a plurality of light sources, a plurality of light sensors, and a controller coupled to the plurality of light sources and the plurality of light sensors. The controller is configured to monitor one or more parameters between a rotor and a casing at least partially based on an interruption or a transmission of one or more paths of light from the plurality of light sources to the plurality of light sensors.

BACKGROUND

The subject matter disclosed herein relates to clearance measurementsand, more specifically, to measurements of clearance between rotatingand stationary components in a rotary machine, such as a compressor of agas turbine engine.

Compressors are used in a variety of industries and systems to compressa gas, such as air. For example, gas turbine engines typically include acompressor to provide compressed air for combustion and cooling.Compressors include a rotor assembly and a stator assembly. Inmulti-stage compressors, the rotor assembly may include multiple rows(e.g., rotor stages), each row having multiple rotor blades attached toone or more rotor wheels that define a shaft. Likewise, the statorassembly may include multiple rows (e.g., stator stages), each rowhaving multiple stator vanes attached to a casing that circumscribes therotor blades. The rotor assembly is designed to rotate with respect tothe stator assembly, compressing an intake fluid as the fluid traversesthe compressor. A clearance between the rotor assembly and the statorassembly may be associated with an efficiency of the compressor.However, sensors used to measure the clearance require a radial bore forinstallation, which creates a potential leak path.

BRIEF DESCRIPTION

Certain embodiments commensurate in scope with the originally claimedsubject matter are summarized below. These embodiments are not intendedto limit the scope of the claimed invention, but rather theseembodiments are intended only to provide a brief summary of possibleforms of the subject matter. Indeed, the present system may encompass avariety of forms that may be similar to or different from theembodiments set forth below.

In a first embodiment, a system includes a measurement system having aplurality of light sources, a plurality of light sensors, and acontroller coupled to the plurality of light sources and the pluralityof light sensors. The controller is configured to monitor one or moreparameters between a rotor and a casing at least partially based on aninterruption or a transmission of one or more paths of light from theplurality of light sources to the plurality of light sensors.

In a second embodiment, a system includes a measurement system having asensor mount with a top surface, a plurality of light sources coupled tothe sensor mount, and a plurality of light sensors coupled to the sensormount. The plurality of light sources are circumferentially spaced apartfrom the plurality of light sensors. Each of the plurality of lightsources is configured to transmit light along a path of light to one ofthe plurality of light sensors, wherein the paths of light are spacedfrom the top surface at a plurality of heights.

In a third embodiment, a method includes transmitting light from aplurality of light sources toward a plurality of light sensors along aplurality of paths of light positioned at a plurality of radial heightsrelative to a curved surface along a rotational path between a rotor anda casing. The method further includes monitoring one or more parametersbetween the rotor and the casing at least partially based on aninterruption or a transmission of one or more of the plurality of pathsof light.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present subjectmatter will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a gas turbine systemhaving a multi-stage axial compressor with a sensor assembly coupled toa controller;

FIG. 2 is a cross-sectional side view of an embodiment of the gasturbine engine of FIG. 1, illustrating stages of blades of a rotorassembly and vanes of a stator assembly of the multi-stage axialcompressor;

FIG. 3 is a perspective view of an embodiment of a portion of a casingof the compressor of FIG. 1, illustrating a plurality of sensor mountscoupled to an internal surface of the casing;

FIG. 4 is a partial perspective view of an embodiment of the casing ofFIG. 3, taken within line 4-4, illustrating a circumferential end of oneof the sensor mounts of FIG. 3 coupled to the casing;

FIG. 5 is a cross-sectional schematic view of an embodiment of thesensor assembly having a light source and a light sensor coupled to oneof the sensor mounts in the casing of FIG. 3, illustrating a blade ofthe rotor assembly moving along an inner circumference of the casingcrossing a light path between the light source and the light sensor;

FIG. 6 is a graph representative of an embodiment of data obtained fromthe sensor assembly of FIG. 5, illustrating a duration of obstruction ofthe light path used to determine a clearance between the casing and theblade of the rotor assembly;

FIG. 7 is a flow chart of an embodiment of a process to measure aclearance between the casing and the blade of the rotor assembly of FIG.5;

FIG. 8 is a cross-sectional schematic view of an embodiment of thesensor assembly having a plurality of light sources and a plurality oflight sensors coupled to one of the sensor mounts in the casing of FIG.3, illustrating a blade of the rotor assembly moving along an innercircumference of the casing crossing one or more light paths between thelight sources and the light sensors;

FIG. 9 is an embodiment of a look-up table that may be used to measurethe clearance between the casing and the blade based on data obtainedfrom the sensor assembly of FIG. 8;

FIG. 10 is a cross-sectional schematic view of an embodiment of thesensor assembly having a plurality of light sources and a plurality oflight sensors coupled to one of the sensor mounts in the casing of FIG.3, illustrating a blade of the rotor assembly moving along an innercircumference of the casing crossing one or more light paths between thelight sources and the light sensors;

FIG. 11 is a flow chart of an embodiment of a process to measure aclearance between the casing and the blade and a roundness of the casingas illustrated in FIG. 10;

FIG. 12 is a cross-sectional schematic view of an embodiment of thesensor assembly having a common light source and a plurality of lightsensors coupled to one of the sensor mounts in the casing of FIG. 3,illustrating a blade of the rotor assembly moving along an innercircumference of the casing crossing at least a portion of a light pathbetween the common light source and the light sensors;

FIG. 13 is a cross-sectional schematic view of an embodiment of thesensor assembly having a common light source and a plurality of lightsensors coupled to one of the sensor mounts in the casing of FIG. 3,illustrating a blade of the rotor assembly moving along an innercircumference of the casing crossing at least a portion of a light pathbetween the common light source and the light sensors;

FIG. 14 is a graph representative of an embodiment of data obtained fromthe sensor assembly of FIGS. 12 and 13 that may be used to determine aclearance between the casing and the blade of the rotor assembly;

FIG. 15 is a schematic view of an embodiment of a plurality of lightsensors of the sensor assembly of FIGS. 12 and/or 13, illustrating thelight sensors arranged in a tightly packed column or array;

FIG. 16 is a schematic view of an embodiment of a plurality of lightsensors of the sensor assembly of FIGS. 12 and/or 13, illustrating thelight sensors arranged in a tightly packed cluster or two-dimensionalbundle;

FIG. 17 is a flow chart of an embodiment of a process to measure aclearance between the casing and the blade of the rotor assembly ofFIGS. 12 and 13; and

FIG. 18 is a schematic view of an embodiment of a measurement systemthat may be utilized to measure a clearance between a rotor assembly(e.g., rotor, blades, or both) and a casing surrounding the rotorassembly.

DETAILED DESCRIPTION

One or more specific embodiments of the present subject matter will bedescribed below. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions must be madeto achieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

When introducing elements of various embodiments of the present subjectmatter, the articles “a,” “an,” “the,” and “said” are intended to meanthat there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

The disclosed embodiments are directed to measuring a clearance betweena rotor assembly (e.g., a rotor, blades, or both) and a stator assembly(e.g., a casing, vanes, or both) of a machine, such as a compressor, apump, a turbine, or another rotary machine. For example, the disclosedembodiments include optical or light-based measurements of a clearancebetween rotor blades and a casing of a compressor.

In certain embodiments, a compressor of a turbine system may includemultiple stages or rows of rotor blades configured to be rotated tocompress a gas (e.g., air), which is then delivered to fuel nozzlesand/or combustors for combustion processes. During rotation, the tips ofthe rotor blades (e.g., compressor blades) are spaced a relatively smalldistance away from an internal surface of a casing of the compressor.Particularly, the spacing or clearance between the compressor blade tipsand the casing may be minimal, such that the rotor blades efficientlycompress the air while not contacting the casing.

In some instances, the clearance between the rotor blades and the casingmay change over time. For example, during normal operation, theclearance may change due to thermal expansion and contraction of therotating and stationary parts of the machine, e.g., the casing, theblades, etc. The clearance also may vary over each revolution of therotor if the geometry of the rotor or casing becomes less round, i.e.,out-of-round condition. A more severe out-of-round condition will resultin a greater variation in the clearance per revolution of the rotor.Other causes for variation in the clearance may include degradation ofthe rotor blades, vibrations or oscillations in the compressor, cracksor broken tips of the rotor blades, and rub conditions resulting inpartial removal of the tips of the rotor blades.

In some instances, to detect the clearance between the rotor blades andthe casing, an operator may drill holes angled radially toward alongitudinal axis of the compressor. The operator may then insertsensors (e.g., proximity sensors) into the holes to detect blade tipclearance in the radial direction. However, such clearance measurementmethods may be inaccurate and inefficient. That is, it may be difficultto ensure the radial orientation of the holes and of the sensors as wellas the circumferential locations of the holes and of the sensors. Assuch, the inconsistencies between orientations and locations of thesensors may provide difficulty in calibrating gathered measurement data.Moreover, the radial holes create a potential leak path in the casing,which can create additional maintenance issues. An excess of radialholes in the casing can also impact the structural integrity of thecasing.

Accordingly, as discussed in further detail below, the disclosedembodiments include systems and methods for determining blade tipclearance of a compressor using secant-oriented sensors and lightsources disposed within internal tracks of a casing of the compressor.For example, in certain embodiments, the system may utilize tracks(e.g., channels) disposed circumferentially along an internal surface ofthe casing. The tracks may be configured to receive arcuate mounts thatmay hold a sensor assembly configured to be utilized to determine bladetip clearance. The sensor assembly may include one or more light sourcesand one or more light sensors and may be communicatively coupled to acontroller. That is, the sensor assembly and the controller maycollectively form a measurement system configured to determine blade tipclearance. The light sources and the light sensors are configured togather data indicative of blade tip clearance, and the controller isconfigured to determine the blade tip clearance and other measurementsbased on the gathered data.

To illustrate, the light sources are configured to direct light from afirst location (e.g., a first circumferential position or area) on aninternal surface of the casing to a second location (e.g., a secondcircumferential position or area) on the internal surface of the casing.Indeed, the light sensors may be located at the second location todetect the light. In other words, one or more light sources may emit oneor more lights as secants across the internal surface (e.g., curvedsurface or inner circumference) of the casing towards one or more lightsensors.

In certain embodiments, a light source may emit a collimated lighttoward a corresponding light sensor. The collimated light may beinterrupted (e.g., blocked) by individual rotor blades passing throughthe collimated light. Accordingly, the blade tip clearance to theinternal surface of the casing may be based on a duration of time thatthe collimated light is broken or interrupted. Further, in certainembodiments, multiple light sources may emit multiple collimated lightsthat are radially stacked parallel to one another (e.g., parallel beamsof light at different radial heights) across the internal surface of thecasing toward multiple, similarly stacked light sensors. The stackedcollimated lights may be broken by the rotor blades passing through thecollimated lights. Accordingly, the blade tip clearance to the internalsurface of the casing may be based on respective positions of thecollimated lights that are broken by the rotor blades.

Further still, in certain embodiments, the light source may emit a lighttowards a group (e.g., an array) of sensors. The light may be adiverging light, such as a light beam that is conical in shape. Aportion of the light may be broken by the rotor blades passing throughthe light. Accordingly, the blade tip clearance may be based on a numberof sensors of the group of sensors that are not detecting light as therotor blade passes through the light.

Further, in some embodiments, in addition to blade tip clearance, themeasurement system may detect roundness or curvature of the casing,e.g., an out-of-round condition (e.g., deviation from a circular shape)and severity of such condition. For example, in some embodiments, acurvature of the casing may change (e.g., deform) over time due tostresses experienced during normal operation. As discussed in furtherdetail below, the measurement system is configured to detect suchchanges in the roundness. In some embodiments, the measurement systemmay monitor the blade tip clearance and the curvature of the casing overtime and may identify variations in the blade tip clearance andcurvature over time. These variations of blade tip clearance and thecurvature of the casing may be evaluated to detect oscillations and/orvibrations in the compressor.

FIG. 1 is a block diagram of an embodiment of a turbine system 10 thatincludes a gas turbine engine 12 and a controller 14 (e.g., electronicand/or processor-based controller). The illustrated gas turbine engine12 includes a compressor 20 (e.g., a multi-stage axial compressor orcompressor section), a turbine 22 (e.g., a multi-stage turbine orturbine section), and fuel nozzles 24 coupled to one or more combustors26 (e.g., a combustor section). The compressor 20 and turbine 22 eachmay have any number of stages (e.g., rows) of rotor blades and statorvanes (e.g., 1 to 20). The controller 14 may be communicatively coupledto sets of light sources 16 (e.g., lasers) and light sensors 18 (e.g.,fiber optic sensors/detectors) disposed in a casing of the compressor20.

For example, data collected by the light sensors 18 may be used todetermine a clearance between rotor blades and a casing of thecompressor 20. As discussed in detail below, the controller 14 mayreceive the data from the light sensors 18, and may determine (e.g.,calculate or measure) a blade tip clearance and other operationalparameters of the compressor 20 based on the collected data. Asdiscussed herein, the light sensors 18, the light sources 16, and thecontroller 14 collectively form a measurement system 27. Although thefollowing discussion presents embodiments of the measurement system 27in context of the compressor 20, the measurement system 27 (e.g., lightsources 16, light sensors 18, and controller 14) may be coupled to anyrotary machine, such as the turbine 22, a pump, a steam turbine, a hydroturbine, or any combination thereof. Before presenting details of themeasurement system 27, the following discussion provides a briefdescription of the gas turbine engine 12 and its operation.

In operation, the compressor 20 is configured to compress a compressiblefluid (e.g., gas such as air, oxygen, and/or exhaust gas), and deliverthe compressed fluid to the fuel nozzles 24 and/or the combustors 26.Although the compressible fluid may include any suitable gas, thefollowing discussion may generally refer to the compressible fluid as anoxidant (e.g., air) as one non-limiting example. The fuel nozzles 24 areconfigured to supply fuel (e.g., from one or more fuel supplies) intothe one or more combustors 26 (e.g., in combustion chambers), whichcombust the fuel with the oxidant (e.g., air) to generate hot combustiongases to drive the turbine 22. The fuel nozzles 24 may be designed aspre-mix fuel nozzles 24 and/or diffusion fuel nozzles 24. Pre-mix fuelnozzles 24 mix the fuel with the oxidant (e.g., air) to create pre-mixtype flames. Diffusion fuel nozzles 24 do not premix the fuel with theoxidant, and thus create diffusion type flames. Regardless of the typeof flames, the hot combustion gas flows from the combustors 26 into theturbine 22, thereby driving rotation of one or more stages of turbineblades coupled to a turbine rotor and shaft 30 along an axis 32.Eventually, the hot combustion gas exits the turbine 22 through anexhaust outlet 28 (e.g., exhaust stack, exhaust end).

In the illustrated embodiment, the shaft 30 is coupled to the compressor20 and a load 36, such that rotation of the shaft 30 also drivesrotation of the compressor 20 and the load 36. The compressor 20 mayintake the oxidant (e.g., air) through an air intake 34, which mayinclude filters, thermal control systems, or any other preconditioningsystems. The load 36 may include an electrical generator, a rotarymachine, a propulsion system of a vehicle, or any other suitable device.

The compressor 20 may include alternating rows of rotating blades andstationary vanes (e.g., airfoils) that may be disposed in multiplestages, described in more detail below. The oxidant (e.g., air) may beprogressively compressed in stages or rows of rotating blades andcorresponding stator vanes as the air moves downstream in the compressor20. In the depicted embodiment, the compressor 20 is a multi-stage axialcompressor 20 having at least two rows or stages of blades and vanes.For example, in certain embodiments, the multi-stage axial compressor 20may have any number (e.g., any number from 2 to 14 or more) of rows orstages of compressor blades and vanes.

It may be beneficial to illustrate a more detailed view of certaincomponents of the gas turbine engine 12. Accordingly, FIG. 2 is across-sectional side view of an embodiment of the compressor 20 of thegas turbine engine 12 of FIG. 1. Throughout the discussion of FIG. 2, aset of axes will be referenced. These axes are based on a cylindricalcoordinate system and point in an axial direction 38 (e.g., downstream),a radial direction 40, and a circumferential direction 42. For example,the axial direction 38 extends downstream through the compressor 20generally parallel to the axis 32, the radial direction 40 extends awayfrom the axis 32, and the circumferential direction 42 extends aroundthe axis 32.

In operation, air enters the compressor 20 in the axial direction 38through the air intake 34 and may be pressurized in the multi-stageaxial compressor 20. The compressed air may then be mixed with fuel forcombustion within the combustor 26 to drive the turbine 22 to rotate theshaft 30 in the circumferential direction 42 and, thus, the multi-stageaxial compressor 20 and the load 36. The rotation of the shaft 30 alsocauses one or more blades 44 (e.g., compressor rotor blades) within themulti-stage axial compressor 20 to draw in and pressurize the airreceived by the air intake 34.

The multi-stage axial compressor 20 may include a rotor assembly 46having multiple rotor blades 44 surrounded by a static casing 48 (e.g.,stator, housing or outer wall) having multiple stator vanes 50. In someembodiments, the static casing 48 of the compressor 20 or the air intake34 may have one or more sets of inlet guide vanes 52 (IGVs) (e.g.,variable IGV stator vanes) that may control flows into the compressor20. The compressor 20 may include a plurality of rows or stages 54, suchas between 2 to 30, 2 to 25, 2 to 20, 2 to 14, or 2 to 10 rows orstages, or any specific number or range therebetween. In each stage, themulti-stage axial compressor 20 may include 2 to 1000, 5 to 500, or 10to 100 rotor blades 44, and a corresponding and adjacent set of 2 to1000, 5 to 500, or 10 to 100 stator vanes 50.

In particular, the illustrated embodiment of the multi-stage axialcompressor 20 includes 14 stages (designated as 54 a through 54 n),although greater or fewer stages 54 may be used. It may be appreciatedthat each stage 54 has a set of rotor blades 44 disposed at a firstaxial position and a set of stator vanes 50 disposed at a second axialposition along the length of the compressor 20 adjacent the set of rotorblades 44. In other words, each stage 54 has the rotor blades 44 andstator vanes 50 axially offset from one another, such that thecompressor 20 has an alternating arrangement of rotor blades 44 andstator vanes 50 one set after another along the length of the compressor20. Each set of rotor blades 44 extends (e.g., in a spaced arrangement)in the circumferential direction 42 about the shaft 30, and each set ofstator vanes 50 extends (e.g., in a spaced arrangement) in thecircumferential direction 42 within the static casing 48.

In use, the rotor blades 44 may rotate circumferentially about the axis32 and relative to the static casing 48 and the stator vanes 50.Rotation of the rotor blades 44 may result in air entering the airintake 34. The air is then subsequently compressed as it traverses thevarious stages 54 of the compressor 20 and moves in the axial direction38 downstream of the multi-stage axial compressor 20. The compressed airmay then exit through an outlet 56 of the multi-stage axial compressor20. The outlet 56 may have a set of exit guide vanes 58 (EGVs). Thecompressed air that exits the compressor 20 may be mixed with fuel,directed to the combustor 26, directed to the turbine 22, or usedelsewhere in the turbine system 10.

The compression of the air as it travels through the compressor 20 maybe based at least in part on clearances between the rotor (e.g., therotor blades 44) and the stator (e.g., the casing 48 and the statorvanes 50) of the compressor 20. Minimization of these clearance mayresult in increased compression of the air. More specifically, theclearance between the rotor blades 44 and an internal surface 70 of thecasing 48 may have a direct correlation with an air compressionefficiency of the compressor 20. Indeed, the lesser the clearancebetween the rotor blades 44 and the internal surface 70, the greater theefficiency of the compressor 20 in compressing the air. As such, theclearance (e.g., a blade tip clearance) between the rotor blades 44 andthe internal surface 70 of the casing 48 may be monitored. In someembodiments, operation of the compressor 20 may be based on the bladetip clearance to enhance an efficiency of the compressor 20. Forexample, in some embodiments, a position of the rotor blades 44 may beadjusted or maintenance may be performed on the compressor 20, based onthe blade tip clearance.

As discussed herein, the casing 48 of the compressor 20 is configured tohouse the light sensors 18 and the light sources 16, which are used togather data indicative of clearances between the rotor blades 44 and theinternal surface 70 of the casing 48. Keeping this in mind, FIG. 3 is aperspective view of an embodiment of the casing 48 of the compressor 20.Particularly, FIG. 3 is a perspective view of a casing portion 80 of thecasing 48 of the compressor 20. Indeed, in some embodiments, the casing48 may be composed of multiple casing portions 80, which may be coupledtogether to form the casing 48. For example, the casing 48 may includetwo, three, four, or more casing portions 80 spaced circumferentially 42about the axis 32 to form a full circumference of the casing 48. Thecasing 48 extends circumferentially 42 about the rotor assembly 46 ofthe compressor 20.

As illustrated in FIG. 3, the casing 48 may include one or more mounts82 (e.g., arcuate mounts, inserts) coupled to the internal surface 70 ofthe casing 48. Further, the casing 48 may include rotor blade areas 83and stator vane areas 84 extending in the circumferential direction 42about the internal surface 70 and alternating along the axial direction38. The rotor blade areas 83 may be areas along which tips of the rotorblades 44 (FIG. 2) are configured to pass. In other words, the rotorblade areas 83 may be axially 38 and radially 40 aligned with the rotorblades 44 when the casing 48 is coupled to the rotor assembly 46.Although not explicitly shown, the stator vane areas 84 may include thestator vanes 50 (FIG. 2) extending from the internal surface 70 of thecasing 48. Indeed, it should be noted that the illustration has beenintentionally simplified to focus attention on certain aspects, asdiscussed herein. That is, the casing 48 may include additional elements(e.g., the stator vanes 50) that are not explicitly shown in theexemplary illustration.

The mounts 82 may be coupled to the internal surface 70 of the casing 48at the rotor blade areas 83. In some embodiments, location of the mounts82 may define the rotor blade areas 83. The mounts 82 may furtherinclude housing structures 86 configured to provide housing to sensorassemblies 88 (e.g., the light sensors 18 and/or the light sources 16).The housing structures 86 may be imbedded within the mounts 82 such thatthe sensor assemblies 88 may be disposed beneath the internal surface 70of the casing 48. In other words, the sensor assemblies 88 may bedisposed radially 40 between the internal surface 70 of the casing andan external surface 90 of the casing 48. Accordingly, as will beappreciated, the sensor assemblies 88 are configured to detect apresence and clearance of the rotor blades 44 as the rotor blades 44pass along the mount 82.

A curvature of the mounts 82 may substantially match the curvature ofthe internal surface 70 of the casing 48. In this manner, when themounts 82 are coupled to the casing 48 (as shown), a top surface 100 ofthe mounts 82 may be substantially flush with the internal surface 70 ofthe casing 48. Particularly, the internal surface 70 of the casing 48may include tracks 102 (e.g., channels) configured to receive the mounts82. Particularly, each track 102 may be disposed along the internalsurface 70 of the casing 48 in the circumferential direction 42, such aswithin the rotor blade areas 83.

In some embodiments, each track 102 may be configured to receivemultiple mounts 82. That is, each mount 82 may include oppositecircumferential ends 104. In some embodiments, the circumferential ends104 of adjacent mounts 82 may be in contact or may be coupled togetherwhen the mounts 82 are inserted into the tracks 102. Indeed, as shown,each mount 82 may include any suitable respective arcuate lengthextending between the circumferential ends 104. In this way, anysuitable number of mounts 82 may be inserted into each track 102. Forexample, each casing portion 80 may include a single mount 82 in eachtrack 102, e.g., sized to substantially match a circumferential 42length of the casing portion 80. Alternatively, each casing portion 80may include 2, 3, 4, 5, 6 or more mounts 82 of equal or differentcircumferential 42 length sized to collectively fit within each track102 in the casing portion 80. Furthermore, the disclosed embodiments mayinclude a plurality of different families of mounts 82, each familydesigned for a particular configuration of sensor assemblies 88, asdiscussed in further detail below.

Further, in some embodiments, the mounts 82 may include circumferentialslots disposed opposite to the top surface 100 (e.g., within a bottomsurface 110) configured to organize and route wires (e.g., conductors)coupled to the sensor assemblies 88. In this way, the wires frommultiple locations of the housings 86 of the mount(s) 82 within one ofthe tracks 102 may be grouped together. As such, the wires from thesensor assemblies 88 disposed within one of the tracks 102 may be routedthrough a single or common bore in the casing 48 to, for example, thecontroller 14. In contrast to sensors requiring a radial bore for eachindividual sensor, the disclosed embodiment enables a substantialreduction in the number of bores and thus a reduction in the number ofpotential leak paths in the casing 48. To further illustrate, FIG. 4 isa partial cut-away perspective view of the casing 48 of FIG. 3, takenwithin dashed line 4-4, illustrating the circumferential end 104 of oneof the mounts 82.

As shown, the mount 82 may be coupled to the track 102 such that the topsurface 100 of the mount 82 is substantially flush with and contoured tomatch (e.g., to have substantially the same inner curvature of) theinternal surface 70 of the casing 48. To couple with the track 102, themount 82 may include opposite flanges 112 configured to engage withopposite recesses 114 of the track 102. In the illustrated embodiment,the opposite flanges 112 and the opposite recesses 114 extend in theaxial 38 upstream and downstream directions, while also extendingcircumferentially 42 along a length of the mount 82 and the track 102.

Further, as shown, the bottom surface 110 of the mount 82 may include acircumferential slot 116. As mentioned above, the slot 116 may beconfigured to route wires 118 from sensor assemblies 88 disposed withinthe housing 86. In some embodiments, the slot 116 may be defined by aspace disposed between the bottom surface 110 of the mount 82 and thetrack 102 and between the opposite flanges 112. In some embodiments, theslot 116 may be disposed completely internal to the mount 82 such thatwalls of the mount 82 encompass the slot 116. In this way, the wires 118from a portion or all of the sensor assemblies 88 disposed within arespective track 102 may be grouped together and routed through a singleoutlet through the casing 80 to communicatively couple to an externaldevice, such as the controller 114.

As will be appreciated, the housing 86 of the mounts 82 may allow forthe light sensor 18 and the light source 16 to be oriented as secants(e.g., geometric chords) across the circumference of the internalsurface 70. In other words, the sensor assemblies 88 may send andreceive light across the internal surface 70 such that the light is notradially 40 oriented toward the axis 32 of the compressor 20. In certainembodiments, a portion or all of each mount 82 may be constructed of atransparent material configured to transmit light between the lightsource 16 and the light sensor 18, while also conforming to the innercurvature of the casing 48.

Generally, the sensor assemblies 88 are configured to transmit andreceive light substantially linearly across the internal surface 70 ofthe casing 48. A portion of the light may pass through the transparentmaterial of the mount 82, while the remaining portion (e.g., a majority)of the light may pass directly through the interior volume of the casing48 in a tangential direction to facilitate clearance measurements. Therotor blades 44 may pass through (e.g., interrupt, block) the light. Thelight sensors 18 may gather various data as an effect of the rotorblades 44 passing through the light. The controller 14 may then receivethe data and calculate the blade tip clearance, out of roundness,vibration, and other parameters, based on the various data received fromthe light sensors 18. For example, the received data may include aduration of light blockage of each beam of light between light sources16 and light sensors 18, a number and position of blocked light beamsbetween one or more light sources 16 and a plurality of light sensors18, or a combination thereof. The controller 14 also may acquire otheroperational data, such as a rotational speed of the rotor and/or rotorblades 44.

FIG. 5 is a cross-sectional schematic view of an embodiment of thesensor assembly 88 of the measurement system 27 having a light source 16and a light sensor 18 coupled to one of the sensor mounts 82 in thecasing 48 of FIG. 3, illustrating a blade 44 of the rotor assembly 46moving along an inner circumference 70 of the casing 48 crossing a lightpath 120 (e.g., a secant along the inner circumference 70) between thelight source 16 and the light sensor 18. The sensor assembly 88 isconfigured to detect a blade tip clearance 119 of a rotor blade 44 of arotor assembly 46. For simplicity, FIG. 5 illustrates one rotor blade 44of the rotor assembly 46. However, the rotor assembly 46 includes aplurality of rotor blades 44 coupled to a central rotor, hub, or shaft,wherein the rotor blades 44 are circumferentially 42 spaced about theaxis 32. The blade tip clearance 119 may be defined as a distance,measured in the radial direction 40, from a distal end 121 of the rotorblade 44 to the internal surface 70 of the casing 48 and/or the topsurface 100 of the mount 82.

As illustrated in the current embodiment, the sensor assembly 88 mayinclude at least one light source 16 (e.g., a single light source 16)and at least one light sensor 18 (e.g., a single light sensor 18).Particularly, the sensor assembly 88 may be disposed in the housing 86provided via the mount 82. In some embodiments, light source 16 and thelight sensor 18 may be disposed in respective, distinct housings 86. Insome embodiments, the light source 16 and the light sensor 18 may bedisposed in a common housing 86. The light source 16 and the lightsensor 18 may be substantially flush or recessed relative to theinternal surface 70 (e.g., inner circumference) of the casing 48 and/orthe mount 82.

Furthermore, the mount 82 may include a transparent portion 123extending along the light path between the light source 16 and the lightsensor 18. For example, in the illustrated embodiment and eachembodiment disclosed herein, the entire mount 82 may be formed of atransparent material, or the mount 82 may include a transparent portion123 (e.g., a transparent insert or injected transparent material) in arecess or slot 125 extending between the light source 16 and the lightsensor 18. The outer surface of the transparent portion 123 may becontoured to substantially match the curvature of the internal surface70 (e.g., inner circumference) of the casing 48 and/or the mount 82.

As shown, the light source 16 is configured to direct light 120 (e.g., alight beam, collimated light, a laser light) along a light path towardthe light sensor 18. As context herein dictates, the reference number120 will refer to either the light produced by the light source 16 orthe light path between the light source 16 and the light sensor 18. Asdiscussed herein, the light 120 may be collimated light, such as lightwith substantially no divergence and substantially parallel light rays.The light sensor 18 is configured to detect whether the light sensor 18is receiving the light 120. That is, the rotor blade 44 may pass throughthe light 120, thereby preventing the light sensor 18 from receiving thelight 120 while the rotor blade 44 is disposed within the path of thelight 120 (i.e., blocking, obstructing or interrupting the light).

To illustrate, the rotor blade 44 may be configured to travel along arotor path 122. The rotor path 122 may be substantially concentric withthe internal surface 70 of the casing 48. However, as discussed below,in some embodiments, the rotor assembly 46 may oscillate or vibrate,which may similarly cause fluctuations in the rotor path 122. The rotorblade 44 is configured to travel continuously along the rotor path 122from a first position 124 sequentially through a second position 126, athird position 128, a fourth position 130, a fifth position 132, a sixthposition 134, and a seventh position 136. Indeed, although shown asdistinct positions, it should be understood that the rotor blade 44 maycontinuously travel from the first position 124 through the seventhposition 136 at a substantially constant rotational speed duringclearance measurements. Further, it should be noted that the rotor path122 may extend in the circumferential direction 42 along an entirety ofthe casing 48.

As shown, the rotor blade 44 may be disposed outside of the light 120(e.g., not obstructing or blocking the light 120) while in the firstposition 124. The rotor blade 44 may then be disposed within the light120 (e.g., obstructing or blocking the light 120) while in the secondposition 126 through the sixth position 134. While the rotor blade 44 isdisposed within (e.g., blocking or interrupting) the light path of thelight 120, the light sensor 18 does not receive (e.g., detect) the light120. The rotor blade 44 may then be disposed outside of the light 120while in the seventh position 136.

The light sensor 18 may send (e.g., communicate, transmit) a signal tothe controller 14, wherein the signal is indicative of the duration oftime that the light sensor 18 is receiving light and/or is not receivinglight. For example, the light sensor 18 may send a signal to thecontroller 14 indicating the presence or absence of light, which may inturn correlate the signal (e.g., presence or absence of light) to aclock indicating a duration of the presence of light and a duration ofthe absence of light. The controller 14 also may receive sensor datafrom one or more additional sensors measuring parameters of the turbinesystem 10, such as a rotational speed of the compressor 20. Thecontroller 14 may then compare the duration of the absence of lightacquired from the light sensor 18 with the rotational speed of the rotorblade 44 to calculate the blade tip clearance 119. Indeed, the durationof time that the rotor blade 44 is obstructing the light 120 may bedirectly correlated to the blade tip clearance 119.

That is, a greater duration of time that the light 120 is blocked by therotor blade 44 indicates a smaller blade tip clearance 119, while alesser duration of time that the light 120 is blocked by the rotor blade44 indicates a greater blade tip clearance 119. For example, if thelight sensor 18 detects an absence of light for a duration of time thatcorresponds to an entire distance from the light source 16 to the lightsensor 18 when considering the rotational speed of the rotor blade 44,then the controller 14 would calculate a blade tip clearance 119 at aminimum (e.g., approximately zero or substantially close to zero). Incontrast, if the light sensor 18 detects an absence of light for aduration of time that corresponds to a negligible distance (e.g., 0.01percent of the entire distance) from the light source 16 to the lightsensor 18 when considering the rotational speed of the rotor blade 44,then the controller 14 would calculate a blade tip clearance 119 at amaximum (e.g., radial 40 distance between the internal surface 70 andthe light path of the light 120) detectable by the measurement system27. In a similar manner, the controller 14 is configured to calculate ablade tip clearance 119 between the minimum and the maximum when theduration of time of the absence of light falls somewhere between theexamples noted above.

In certain embodiments, the controller 14 may store data correlating abeam height 127 to each position along the light path of light 120 fromthe light source 16 to the light sensor 18, a circumferential distancebetween the light source 16 and the light sensor 18, and a correlationbetween a particular beam height 127 and a circumferential distancebetween a starting point 129 and an ending point 131 of an interruptionof the light path of light 120. Based on this correlation, therotational speed, and the measured duration of time of absence of light,the controller 14 may be programmed to calculate the blade tip clearance119. In some embodiments, the controller 14 may include a lookup table,an equation, a computer model, or other calculation technique configuredto determine the blade tip clearance 119 based on the rotational speed,the measured duration of time of absence of light, and various knownparameters.

Each of the sensor assemblies 88 may be configured to gather dataindicative of the blade tip clearance 119 at respective clearancelocations 144 (e.g., areas having circumferentially 42 spaced lightsources 16 and light sensors 18) along the internal surface 70 of thecasing 48. In the currently illustrated embodiment, the clearancelocation 144 may be defined by a circumferential distance (e.g., anangular distance or arc length) along the internal surface 70 of thecasing 48 between the light source 16 and the light sensor 18. As such,the controller 14 may determine an approximation (e.g., an average) ofthe blade tip clearance 119 relative to the circumferential distanceincluded in the clearance location 144 of the casing 48.

For example, in certain embodiments, the angular distance of eachclearance location 144 may be 1 to 15 degrees, 1 to 10 degrees, or 1 to5 degrees. In certain embodiments, the arc length of each clearancelocation 144 may be greater than zero and less than 1, 2, 3, 4, or 5percent of a circumference of the internal surface 70 of the casing 48.The measurement system 27 may include sensor assemblies 88 having equalor different circumferential distances (e.g., angular distances or arclengths) between light sources 16 and light sensors 18, which may belocated at different circumferential positions spaced about thecircumference of the internal surface 70 of the casing 48. In someembodiments, the clearance locations 144 may be disposed at 2, 3, 4, 5,6, 7, 8, 9, 10, or more equally spaced circumferential positions of thecasing 48. For example, the clearance locations 144 may be disposed atfour circumferentially spaced positions of the casing 48, such as 3o'clock, 6 o'clock, 9 o'clock, and 12 o'clock positions.

The controller 14 is configured to monitor sensor data and measure bladetip clearance 119 for the rotor blades 44 over time to: determine trendsin the clearance 119, compare clearances 119 of multiple or all of therotor blades 44 at each stage over each revolution, identifyoscillations or vibrations in the rotor blades 44 and/or casing 48,identify sudden changes indicative of catastrophic events (e.g., bladetip breakage), compare clearances 119 between different stages of thecompressor 20, predict future clearances 119 and the impact oncompressor 20 efficiency, schedule maintenance or repair to correct anyissues with unacceptable clearances 119, and control the system 10 basedon measured clearances 119.

FIG. 6 is a graph 150 representative of an embodiment of data obtainedfrom the sensor assembly 88 of FIG. 5 and received by the controller 14,illustrating a duration of obstruction of the light path 120 used todetermine a clearance 119 between the casing 48 and the blade 44 of therotor assembly 46. The graph 150 may include a light detection axis 152indicative of whether the light sensor 18 is receiving light. The graph150 may further include a time axis 154 indicative of time. As shown,the light detection axis 152 may be binary. That is, the light sensor 18may either be receiving light, indicated by a “1”, or may not bereceiving light, indicated by a “0”. As shown, the light sensor 18 maynot be receiving light from “t1” to “t2” of the time axis 154.Particularly, the rotor blade 44 may be blocking the light from “t1” to“t2”. The controller 14 may determine the blade tip clearance 119 basedon the duration of time that light sensor 18 is not receiving the light120, a rotational speed of the rotor blade 44 measured by a speedsensor, and known parameters of the sensor assembly 88 (e.g., acircumferential distance between the light source 16 and the lightsensor 18, the radius of the inner circumference of the casing 48,and/or the beam height 127 along the light path of light 120).

FIG. 7 is a flow chart of an embodiment of a process 158 to measure aclearance 119 between the casing 48 and the blade 44 of the rotorassembly 46 using the measurement system 27 (e.g., the light sensor 18,the light source 16, and the controller 14) of FIG. 5. At block 160, abeam of light (e.g., the light 120) may be transmitted from a lightsource (e.g., the light source 16) to a light sensor (e.g., the lightsensor 18) along a casing (e.g., the casing 48) surrounding a rotor(e.g., rotor blade 44 of the rotor assembly 46). As discussed herein,the rotor may be any suitable rotor, such as the shaft 30, or otherrotating object. Indeed, as will be appreciated, the embodimentsdiscussed herein may be widely applicable for determining a clearance119 between any suitable rotor and a corresponding casing (e.g.,housing).

At block 162, the process 158 detects a duration of time of interruptionof the beam of light 120. Particularly, the process 158 measures theduration of time that the rotor (e.g., rotor blade 44) blocks the lightsensor 18 from receiving the beam of light 120. In some embodiments, theduration of time may be measured by the light sensor 18 and/or thecontroller 14. At block 164, the process 158 calculates a clearance 119based at least in part on the duration of time of interruption and arotational speed of the rotor. In some embodiments, the rotational speedmay be a directly measured parameter (e.g., via a rotational speedsensor) or may be predetermined. That is, the rotor may be rotating at apredetermined rotational speed.

Further, in some embodiments, the clearance 119 may be used to furthercalculate oscillations or vibrations in the rotor. For example, at block166, the clearance of the rotor may be monitored over time.Particularly, in some embodiments, the clearance 119 between the rotorand the casing 48 may be monitored relative to one or more clearancelocations (e.g., the respective clearance locations 144) in the casing.More specifically, a clearance 119 of a particular point on the rotormay be monitored with respect to several clearance locations of thecasing 48. Additionally, in some embodiments, multiple points (e.g.,multiple rotor blades 44) of the rotor may be monitored with respect tomultiple clearance locations of the casing 48. As will be appreciated,the clearance 119 of a particular rotor point may change overconsecutive revolutions through a clearance location 144 and/or maychange relative to separate clearance locations 144. In other words, therotor may oscillate and/or vibrate relative to the casing 48 such thatthe clearance 119 may change over time.

At block 168, the process 158 may identify a variation in the clearance119 over time. For example, as discussed above, instances of theclearance 119 of the rotor may be monitored relative to the clearancelocations 144 along the casing 48. Accordingly, variation (e.g.,differences, trends in the clearance) between each monitored (e.g.,monitored, measured) instance of the clearance 119 may be monitored withrespect to time. At block 170, the variation identified at block 168 maybe evaluated to determine oscillations in the clearance 119 over theperiod of time. Particularly, the variation of the clearance 119 of therotor over time may indicate that the rotor is oscillating at one ormore frequencies. Accordingly, in some embodiments, the frequencies ofthe oscillations may be determined.

At block 172, the clearance, the variation, and the oscillations of therotor may be output to an output device. For example, in someembodiments, the output device may be a computer (e.g., the controller14) having a user interface. Data indicative of the clearance,variation, and/or oscillations may be displayed via the user interface(e.g., an electronic display or monitor). In some embodiments, the datamay be portrayed in the form of graphs (e.g., clearance, variation,and/or oscillation with respect to time), graphical representations(e.g., 2D or 3D images) of the rotor, or any other suitable manner.

At block 174, operation of the system 10 may be controlled (e.g.,adjusted) based on the output of block 172. For example, in someembodiments, a controller (e.g., the controller 14) may controloperation of the system 10 (e.g., the compressor 20) to correct orcompensate for any undesirable clearances, variations, and/oroscillations of the rotor. In some embodiments, the control of theoperation may be implemented via maintenance or processing a request formaintenance for the rotor.

FIG. 8 is a cross-sectional schematic view of an embodiment of thesensor assembly 88 of the measurement system 27 having a plurality oflight sources 16 and a plurality of light sensors 18 coupled to one ofthe sensor mounts 82 in the casing 48 of FIG. 3, illustrating a blade 44of the rotor assembly 46 moving along an inner circumference 70 of thecasing 48 crossing one or more light paths 120 (e.g., secants along theinner circumference 70) between the light sources 16 and the lightsensors 18. The sensor assembly 88 is configured to detect the blade tipclearance 119 of a rotor blade 44 of a rotor assembly 46. Forsimplicity, FIG. 8 illustrates one rotor blade 44 of the rotor assembly46. However, the rotor assembly 46 includes a plurality of rotor blades44 coupled to a central rotor, hub, or shaft, wherein the rotor blades44 are circumferentially 42 spaced about the axis 32.

As illustrated in the current embodiment, the sensor assembly 88 mayinclude multiple light sources 16 and at least a corresponding number oflight sensors 18 (e.g., a 1:1 ratio of light sources 16 and lightsensors 18). The sensor assembly 88 arranges the light sources 16 andlight sensors 18 in a plurality of pairs, each pair having a lightsource 16 aligned with a light sensor 18 to define a light path of thelight 120. The light paths of the light 120 of the plurality of pairsmay be substantially parallel and offset from one another by smallradial distances (e.g., in radially stacked beams of light 120), whereinthe light paths of the light 120 may be perpendicular to a radius 178 ofthe casing 48 and substantially tangent to an inner circumference alongthe internal surface 70 of the casing 48. The illustrated embodimentincludes five pairs of five light sources 16 aligned with five lightsensors 18 defining light paths 120 a through 120 e. However,embodiments of the sensor assembly 88 may include at least 2, 3, 4, 5,6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, or more light sources 16and light sensors 18 arranged in pairs.

The sensor assembly 88 may be disposed in the housing 86 provided viathe mount 82. In some embodiments, each of the light sources 16 and thelight sensors 18 may be disposed in respective, distinct housings 86. Insome embodiments, more than one of the light sources 16 and/or the lightsensors 18 may be disposed in a common housing 86.

The light sources 16 and light sensors 18 may be substantially flush orrecessed relative to the internal surface 70 (e.g., inner circumference)of the casing 48 and/or the mount 82. Furthermore, the mount 82 mayinclude a transparent material 123 (e.g., a continuous or segmentedpiece of transparent material) extending along the light paths betweenthe light sources 16 and the light sensors 18. For example, in theillustrated embodiment and each embodiment disclosed herein, the entiremount 82 may be formed of a transparent material, or the mount 82 mayinclude a transparent portion 123 (e.g., a transparent insert orinjected transparent material) in a recess or slot 125 extending betweenthe light sources 16 and light sensors 18. The outer surface of thetransparent portion 123 may be contoured to substantially match thecurvature of the internal surface 70 (e.g., inner circumference) of thecasing 48 and/or the mount 82.

As shown, each of the light sources 16 is configured to directrespective lights 120 along light paths toward respective light sensors18. As mentioned above, each of the lights 120 may be substantiallycollimated light, such as with substantially no divergence andsubstantially parallel light rays. Each of the light sensors 18 isconfigured to detect (e.g., receive) the respective lights 120. Indeed,in some embodiments, each light source 16 may be equal in radial height180 with a corresponding light sensor 18 (e.g., when measured from amidpoint along a light path of light 120 between the light source 16 andlight sensor 18). The radial height 180 may be measured in the clearancelocation 144 in the radial direction 40 from the internal surface 70 ofthe casing 48.

In the currently illustrated embodiment, the clearance location 144 maybe defined by the circumferential distance (e.g., an angular distance orarc length) along the internal surface 70 of the casing 48 between thelight source 16 and the light sensor 18 in a particular pair, e.g., anoutermost pair of the light source 16 and light sensor 18. The radialheight 180 of each pair of the light source 16 and the light sensor 18may be defined as the maximum radial height between the light path ofthe light 120 and the internal surface 70, which may correspond to theradial height at the midpoint between the light source 16 and lightsensor 18 of a particular pair. The radial height 180 may progressivelyincrease from one pair to the next in a series of pairs of the lightsource 16 and light sensor 18, and the incremental change (e.g.,increase) in the radial height may be relatively small to provide afiner measurement (or greater accuracy) of the blade tip clearance 119.

Accordingly, the plurality of light paths of light 120 directed from theplurality of light sources 16 to the plurality of light sensors 18 maybe radially spaced from the curved surface (e.g., inner circumference 70or top surface 100) at a plurality of radial heights 180 (e.g., creatingradially stacked, parallel light beams). These radial heights 180 may beaccurately measured and stored in memory of the controller 14 for use incalculating the blade tip clearance 119 during operation of the system10.

In some embodiments, each respective light source 16 may transmit therespective light 120 at a distinct and respective wavelength (e.g.,color of light). Accordingly, in some embodiments, each respective lightsensor 18 may be configured to detect only the respective wavelength ofthe light 120 being emitted from the corresponding light source 16(e.g., the light source 16 at the same radial height 180 as the lightsensor 18). However, embodiments of the measurement system 27 also mayenable each light sensor 18 to detect light from any of the lightsources 16, such that an unexpected detection of a wavelength of light120 at a particular light sensor 18 (or light 120 at an unexpected lightsensor 18) may be indicative of an out-of-round condition (e.g., aninner circumference of the casing 48 is not circular), a vibrationcondition, a misalignment condition, or some other problem.

For example, the sensor assembly 88 includes light sources 16 and lightsensors 18 in a first pair at a first radial height, a second pair at asecond radial height greater than the first radial height, a third pairat a third radial height greater than the second radial height, a fourthpair at a fourth radial height greater than the third radial height, anda fifth pair at a fifth radial height greater than the fourth radialheight. If the light sensor 18 in the third set receives light from thelight source 16 in the first, second, fourth, or fifth set, then thelight sensor 18 or the controller 14 may identify the unexpected receiptof light 120 (e.g., due to the unexpected wavelength) and identify amisalignment or out-of-round condition and its severity, depending onwhich wavelength of light is received by the light sensor 18. Forexample, the controller 14 may be configured to estimate an increasinglygreater severity of the misalignment or out-of-round condition if thereceived wavelength (e.g., at the light sensor 18 in the third set)corresponds to the fifth set rather than the fourth set, or even furtherout in a sixth, seventh, or eighth set of light sources 16 and lightsensors 18.

The rotor blade 44 is configured to rotate along the rotor path 122. Asthe rotor blade 44 moves along the rotor path 122, the rotor blade 44moves through the clearance location 144 and may obstruct one or more ofthe light paths of light 120 that are being transmitted from the lightsources 16 toward the light sensors 18. Accordingly, as the rotor blade44 moves along the rotor path 122 and obstructs one or more of the lightpaths of light 120 (e.g., parallel light paths radially offset from oneanother), one or more of the light sensors 18 may not detect (e.g.,receive) the light 120 due to the obstruction. The position anddetection state (e.g., detecting light or not detecting light) of eachlight sensor 18 in the sensor assembly 88 is indicative of the blade tipclearance 119, because the light path of light 120 between each pair ofthe light source 16 and light sensor 18 is disposed at a differentradial height 180 (e.g., maximum radial height between each pair oflight source 16 and light sensor 18).

In the illustrated embodiment, the sensor assembly 88 includes fivepairs of light sources 16 and light sensors 18 to transmit and receivelight 120 along five different light paths, e.g., a first light path oflight 120 a, a second light path of light 120 b, a third light path oflight 120 c, a fourth light path of light 120 d, and a fifth light pathof light 120 e. However, embodiments of the sensor assembly 88 mayinclude any number of pairs (e.g., any number from 2 to 1000 or more) oflight sources 16 and light sensors 18 arranged with light paths of light120 in sequentially greater radial heights 180 away from the internalsurface 70 of the casing 48, such than the blade tip clearance 119 maybe measured over a greater radial height 180 and/or with a greateraccuracy with closer spacing of the light paths of light 120. Rotorblades 44 having greater blade tip clearances 119 may only pass throughlight paths of light 120 associated with greater radial heights 180(e.g., pairs of light sources 16 and light sensors 18 disposed furtherfrom the internal surface 70). In contrast, rotor blades 44 havinglesser blade tip clearances 119 may pass through the lights associatedwith lesser radial heights 180 as well as the lights 120 associated withthe greater radial heights 180.

In the clearance location 144 shown in FIG. 8, the illustrated rotorblade 44 obstructs the light paths of light 120 a, 120 b, 120 c, and 120d being sensed by the light sensors 18, while not obstructing the lightpath of light 120 e being sensed by the light sensor 18. As a result,the four radially innermost light sensors 18 (i.e., closest to therotational axis 32 and furthest from the internal surface 70) indicate alight obstruction, while the one radially outermost light sensor 18(i.e., furthest from the rotational axis 32 and closest to the internalsurface 70) indicates no light obstruction. Thus, the controller 14receives and processes signals from the light sensors 18 to identify thelight obstructions and their corresponding positions (e.g., radialheights 180) and the light passage and its corresponding position (e.g.,radial height 180) to measure or estimate the blade tip clearance 119.For example, the controller 14 may calculate or estimate the blade tipclearance 119 to be equal to the radial height 180 corresponding to thelight path of light 120 e, which is the only light path of light notobstructed by the rotor blade 44.

However, if multiple light sensors 18 receive light 120 from the lightsources 16, then the controller 14 may receive and process the signalsfrom the light sensors 18 to calculate or estimate the blade tipclearance 119 to be equal to the largest radial height 180 of thenon-obstructed light paths of light 120. As another example, if thelight sensors 18 detect that the rotor blade 44 interrupts the firstpath of light 120 a and the second path of light 120 b, while the lightsensors 18 also detect that the rotor blade 44 does not interrupt thethird path of light 120 c, the fourth path of light 120 d, and the fifthpath of light 120 e, then the controller 14 may receive and process thesignals from the light sensors 18 to calculate or estimate the blade tipclearance 119 of the rotor blade 44 to be equal to the radial height 180corresponding to the light path of light 120 c (i.e., the greatestradial height 180 of the three non-obstructed paths of light 120 c, 120d, and 120 e).

The accuracy of the measurement of blade tip clearance 119 is at leastpartially dependent on the radial spacing between the light paths oflight 120 between the different pairs of light sources 16 and lightsensors 18. Therefore, the closer the radial spacing, the greater theaccuracy of the measurement of blade tip clearance 119. In certainembodiments, the controller 14 may further measure the duration of timeof the obstructions of the light paths of light 120 similar to themanner described above with reference to FIGS. 5-7 in combination withthe measurement techniques described for FIG. 8, to improve the accuracyand/or to provide redundancy in the measurements of the blade tipclearance 119.

FIG. 9 is an embodiment of a look-up table 159 that the controller 14may utilize to determine the blade tip clearance 119 between the casing48 and the blade 44 based on data obtained from the sensor assembly 88of FIG. 8. The controller 14 may store the look-up table 159 in memoryand execute measurement code stored in the memory and executable on aprocessor to determine the blade tip clearance 119 based on the look-uptable and sensor data. As discussed above, each pair of light sources 16and light sensors 18 has a light path of light 120 associated with ablade tip clearance 119, 182 (e.g., the radial height 180). For example,the first light 120 a may be associated with a first clearance 182 a,the second light 120 b may be associated with a second clearance 182 b,the third light 120 c may be associated with a third clearance 182 c,the fourth light 120 d may be associated with a fourth clearance 182 d,and the fifth light 120 e may be associated with a fifth clearance 182e. As shown, the clearances 182 may be in descending order, such thatthe first clearance 182 a is greater than the second clearance 182 b,and so forth.

The controller 14 may receive (from the light sensors 18) dataindicative of whether the respective light sensors 18 are receiving(e.g., detecting) or not receiving the respective lights 120. Thecontroller 14 may then utilize the look-up table 159 based on the datato determine the clearance 182. For example, the data received from thelight sensors 18 may indicate that the light sensors 18 at leasttemporarily did not detect the first light 120 a, the second light 120b, and the third light 120 c, while the light sensors 18 did detect thefourth light 120 d and the fifth light 120 e. Accordingly, thecontroller 14 may determine that the blade tip clearance 119 is lessthan the third clearance 182 c and at least equal to the fourthclearance 182 d, and potentially between the third and fourth clearances182 c and 182 d.

FIG. 10 is a cross-sectional schematic view of an embodiment of thesensor assembly 88 of the measurement system 27 having a plurality oflight sources 16 and a plurality of light sensors 18 coupled to one ofthe sensor mounts 82 in the casing 48 of FIG. 3, illustrating a blade 44of the rotor assembly 46 moving along an inner circumference 70 of thecasing 48 crossing one or more light paths 120 (e.g., secants along theinner circumference 70) between the light sources 16 and the lightsensors 18. As discussed below, the illustrated embodiment of the sensorassembly 88 may be configured to measure the blade tip clearance 119 insubstantially the same manner as described above with reference to FIGS.8 and 9, while further including features to measure roundness (or anout-of-round condition) of the casing 48. For simplicity, FIG. 10illustrates one rotor blade 44 of the rotor assembly 46. However, therotor assembly 46 includes a plurality of rotor blades 44 coupled to acentral rotor, hub, or shaft, wherein the rotor blades 44 arecircumferentially 42 spaced about the axis 32.

As illustrated in the current embodiment, the sensor assembly 88includes a plurality of pairs of light sources 16 and light sensors 18,each pair having a light source 16 aligned with a light sensor 18 todefine a light path of the light 120. The alignment of each pair oflight sources 16 and light sensors 18 and the corresponding light pathof light 120 may define a secant relative to the curvature (e.g.,annular surface) of the internal surface 70 (e.g., inner circumference)of the casing 48 and the top surface 100 of the mount 82. That is, thelight path 120 may intersect the curvature of the internal surface 70 attwo points.

Furthermore, the plurality of pairs of light sources 16 and lightsensors 18 and their corresponding light paths of light 120 may besubstantially parallel and radially spaced apart from one another byintermediate gaps (e.g., radial gaps), thereby defining radially stackedbeams of light 120 at a plurality of radial heights relative to theinternal surface 70. The intermediate gaps may be uniform (or variable)among the plurality of light paths of light 120.

As discussed above, the light sources 16 and the light sensors 18 (e.g.,the sensor assembly 88) may be coupled to the mount 82, which is engagedwith the track 102 in the casing 48. In some embodiments, the sensorassembly 88 may be coupled to an inset 190 (e.g., depression) of themount 82. The inset 190 of the mount 82 may be defined by a space of themount 82 extending below the top surface 100 of the mount 82, whereinthe top surface 100 is contoured to match the curvature of the innercircumference of the casing 48. In some embodiments, the inset 190 ofthe mount 82 may include a transparent material 192, such as thetransparent portion 123 (e.g., a transparent insert or injectedtransparent material) in a recess or slot 125 as discussed above. Thetransparent material 192 may be a solid medium through which the lights120 may be transmitted. The light sources 16 may be positioned in theinset 190 to transmit light paths of light 120 at least partiallythrough the inset 190 (e.g., through the transparent material 192)toward the light sensors 18.

For example, in the illustrated embodiment, the light sources 16 aredisposed on a first side 193 and the light sensors 18 are disposed on asecond side 195 of the inset 190, wherein the first and second sides 193and 195 may be parallel to one another, such that the spacing betweenthe light sources 16 and the light sensors 18 is uniform in the radialdirection 40. However, in certain embodiments, the first and secondsides 193 and 195 may be angled relative to one another (e.g., divergingor converging in the radial inward direction), such that the spacingbetween the light sources 16 and the light sensors 18 varies in theradial direction 40.

Further, in some embodiments, the inset 190 of the mount 82 may includea raised portion 194, which extends radially inwardly away from a base191 of the transparent material 192 and the recess 125 without extendingbeyond the top surface 100 (e.g., flush with the top surface 100). Theraised portion 194 may be configured to block one or more of the lightpaths of light 120 transmitted from the light sources 16 toward thelight sensors 18. That is, in a round condition of the innercircumference of the casing 48, the raised portion 194 may be configuredto block one or more light sensors 18 from receiving the light 120 beingtransmitted from one or more light sources 16. Moreover, as shown, insome embodiments, the sensor assembly 88 may include one or moreauxiliary light sensors 196 not directly paired with a correspondinglight source 16. In some embodiments, the light sensors 18 correspondingto the light paths of light 120 blocked by the raised portion 194 maysimilarly be considered auxiliary light sensors 196. However, the numberof auxiliary light sensors 18, 196, may be greater than thecorresponding number of light sources 16 directed toward the raisedportion 194. The auxiliary light sensors 196 alone or in combinationwith the light sensors 18 may be utilized to detect a change inroundness of the casing 48. Further, although the currently illustratedembodiment includes three auxiliary light sensors 196, it should benoted that the embodiments discussed herein may include any suitablenumber of auxiliary light sensors 196.

In some embodiments, a roundness of the casing 48 may change over time.The roundness of the casing 48 may be defined as a measure of howclosely the shape of the casing 48 (e.g., the inner circumference 70)approaches that of a mathematically perfect circle. The roundness of thecasing 48 may change as the casing 48 experiences thermal expansion andcontraction, thermal stress, or other issues during operation of thecompressor 20. In some embodiments, when the roundness of the casing 48changes, the angle at which the lights 120 are transmitted (e.g., anangle of transmission relative to the casing 48) may similarly change.Particularly, in such embodiments, the angles of the lights 120 maychange such that the auxiliary light sensors 196 or unintended lightsensors 18 may detect one or more of the lights 120. Indeed, detectionof the light 120 at the auxiliary light sensors 196 may indicate achange of the roundness of the casing 48. Further, in some embodiments,as the roundness of the casing 48 changes, light sensors 18 positionedto detect light from a particular light source 16 may instead detectlight from a different light source 16, which may further indicate achange in the roundness of the casing 48.

For example, as mentioned above, in some embodiments, each light 120 maybe associated with a respective wavelength, and the light sensors 18 maycorrespondingly be configured to detect the respective wavelengths.Accordingly, in some embodiments, as the roundness of the casing 48changes, and the angle of the lights 120 changes, the wavelength thatthe respective light sensors 18 may receive may similarly change (e.g.,the light sensors 18 may receive unexpected wavelengths of light 120).Thus, a change in roundness of the casing 48 may be determined by theauxiliary light sensors 196 detecting the light 120 and/or the lightsensors 18 detecting the light 120 from an unexpected light source 16due to a change in the angle of transmission of the lights 120.

The controller 14 may be configured to determine an out-of-roundcondition and its severity by processing the sensed signals from thevarious light sensors 16 and 196, identifying the light source 16 andthe expected position based on the wavelength of the sensed light 120,and calculating an amount of deviation in the roundness based on thedeviation in the light path of light 120. For example, if a particularwavelength of light 120 is expected at a particular light sensor 18 in around condition of the casing 48, then if the particular wavelength oflight 120 is received at a light sensor 18 or 196 a number of positions(or distance) away from the expected sensor position, the number ofpositions (or radial distance) can be used by the controller 14 todetermine the severity of the out of round condition. A greater numberof positions (or radial distance) may signify a greater deviation in theroundness (i.e., a more severe out-of-round condition), whereas a lessernumber of positions (or shorter radial distance) may signify a lesserdeviation in the roundness (i.e., a less severe out-of-round condition).

FIG. 11 is a flow chart of an embodiment of a process 198 to measure aclearance 119 between the casing 48 and the blade 44 and a roundness ofthe casing 48 using the measurement system 27 (e.g., the light sensors18, the light sources 16, and the controller 14) as illustrated in FIG.10. At block 200, a plurality of beams of light (e.g., light paths oflight 120) may be transmitted from a plurality of light sources (e.g.,the light sources 16) toward plurality of light sensors (e.g., the lightsensors 18) along a casing (e.g., the casing 48) surrounding a rotor(e.g., the rotor blade 44 of the rotor assembly 46). As discussedherein, the rotor may be any suitable rotor, such as the shaft 30, orother rotating object. Indeed, as will be appreciated, the embodimentsdiscussed herein may widely applicable for determining a clearancebetween any suitable rotor and a corresponding casing (e.g., housing).

At block 202, the process 198 detects interruptions in the plurality ofbeams of light 120. Particularly, the process 198 detects whether thelight sensors 18 are receiving the plurality of beams of light 120 or ifthe beams of light 120 are being interrupted (e.g., blocked) prior toreaching the plurality of sensors 18. At block 204, the process 198calculates or estimates a clearance based on an identity and position ofthe beams of light 120 successfully reaching the sensors 18 and anidentity and position of the beams of light 120 blocked from reachingthe sensors 18 based on signals from the light sensors 18 and knownpositions (e.g., known radial heights of the light paths of light 120for each pair of light sources 16 and light sensors 18, known blade tipclearances for each light sensor 18, etc.). For example, the process 198may use the look-up table 159 of FIG. 9.

The process 198 may determine that the clearance 119 of the rotor isless than a radial height associated with a beam of light 120 that isinterrupted and thus not detected by the expected light sensor 18, andthe process may determine that the clearance 119 of the rotor is atleast equal to the radial height associated with a beam of light 120that is successfully transmitted and received by the expected lightsensor 18. If the process 198 identifies multiple light sensors 18successfully receiving the expected beams of light, then the process 198may calculate or estimate the blade tip clearance 119 to be equal to thegreatest of the radial heights associated with these light sensors 18.

At block 206, the process 198 evaluates the roundness of the casing 48based on the interruptions and positions of the beams of light 120 and,more specifically, the positions of the light sources 16 emitting thebeams of light 120 and the positions of the light sensors 18 receivingthe beams of light 120. As discussed above, the roundness of the casing48 may affect the angles of transmission of the beams of light 120.Accordingly, the light sensors 18 receiving the beams of light 120 maychange based on the adjusted angles of transmission of the beams oflight 120. The roundness may then be determined based on which of thelight sensors 18 are receiving which of the beams of light 120. In someembodiments, each beam of light 120 may include a respective anddistinct wavelength (e.g., color of light). Accordingly, as the anglesof transmission of the beams of light 120 and the sensors 18 receivingthe beams of light 120 changes, the respective wavelengths that thesensors 18 may detect may similarly change. Thus, in some embodiments,the roundness may be based on the positions of the sensors 18 receivingthe light and the wavelength that the sensors 18 are receiving, whichmay be indicative of the positions of the light sources 16 of therespective wavelengths.

At block 208, the process 198 monitors the clearance 119 of the rotorand the roundness of the casing 48 over a period of time. Particularly,in some embodiments, the clearance 119 between the rotor and the casing48 may be monitored relative to one or more clearance locations (e.g.,the respective clearance locations 144) in the casing 48. Morespecifically, a clearance 119 of a particular point on the rotor may bemonitored with respect to several clearance locations of the casing 48.Additionally, in some embodiments, multiple points (e.g., multiple rotorblades 44) of the rotor may be monitored with respect to multipleclearance locations of the casing 48. As will be appreciated, theclearance 119 of a particular rotor point may change over consecutivepasses through a clearance location and/or may change relative toseparate clearance locations. In other words, the rotor may oscillateand/or vibrate relative to the casing 48 such that the clearance 119 maychange over time. Similarly, in some embodiments, the roundness of thecasing 48 may be monitored at multiple points along the casing 48, whichmay correspond with the clearance locations discussed above.

At block 210, the process 198 may identify a variation in the clearance119 and/or a variation in the roundness over time. For example, asdiscussed above, instances of the clearance 119 of the rotor and theroundness of the casing 48 may be monitored relative to the clearancelocations along the casing 48. Accordingly, variation (e.g.,differences, trends in the clearance and/or roundness) between eachmonitored (e.g., measured) instance of the clearance 119 and/orroundness may be monitored with respect to time. At block 212, thevariation identified at block 210 may be evaluated to determineoscillations in the clearance and/or roundness over the period of time.Particularly, variation of the clearance 119 of the rotor over time mayindicate that the rotor is oscillating at one or more frequencies.Similarly, variations of the roundness of the casing 48 over time mayindicate that the roundness of the casing 48 is oscillating.Accordingly, in some embodiments, the frequencies of the oscillationsmay be determined.

At block 214, the clearance 119, the roundness, the variation, and theoscillations of the rotor and/or the casing 48 may be output to anoutput device. For example, in some embodiments, the output device maybe a computer (e.g., the controller 14) having a user interface. Dataindicative of the clearance 119, the roundness, variation, and/oroscillations may be displayed via the user interface (e.g., anelectronic display or monitor). In some embodiments, the data may beportrayed in the form of graphs (e.g., clearance, roundness, variation,and/or oscillation with respect to time), graphical representations(e.g., 2D or 3D images) of the rotor and/or the casing 48, or any othersuitable manner.

At block 216, operation may be controlled (e.g., adjusted) based on theoutput of block 214. For example, in some embodiments, a controller(e.g., the controller 14) may control operation of the system 10 (e.g.,the compressor 20) to correct or compensate for any undesirableclearances, roundness, variations, and/or oscillations of the rotorand/or the casing. In some embodiments, the control of the operation maybe implemented via maintenance or processing a request for maintenancefor the rotor.

FIG. 12 is a cross-sectional schematic view of an embodiment of thesensor assembly 88 having a common light source 16 and a plurality oflight sensors 18 coupled to one of the sensor mounts 82 in the casing 48of FIG. 3, illustrating a blade 44 of the rotor assembly 46 moving alongan inner circumference 70 of the casing 48 crossing at least a portionof a light path of light 120 (e.g., secants along the innercircumference 70) between the common light source 16 and the lightsensors 18. The common light source 16 (e.g., single or shared lightsource) is configured to emit the light 120 simultaneously toward theplurality of light sensors 18. As shown, the light 120 may be adiverging light or a conically shaped light. In some embodiments, thelight source 16 and the light sensors 18 may be disposed in thehousing(s) 86 of the mount 82. As will be appreciated, the blade tipclearance 119 may be based on the specific light sensors 18 (or a totalnumber of light sensors) detecting the light 120 and/or not detectingthe light 120 as the rotor blade 44 interrupts the light 120. Forexample, the controller 14 may monitor signals from the plurality oflight sensors 18 and determine that the blade tip clearance 119 is atleast equal to a clearance value based on the specific light sensors 18(or a total number of light sensors) that are detecting the light 120.

In operation, the rotor blade 44 may move along the rotor path 122proximate to the clearance location 144 of the casing 48. Indeed, asmentioned above, the sensor assembly 88 may be positioned in the mount82 to detect the blade tip clearance 119 at the clearance location 144of the casing 48. Particularly, the clearance location 144 may bedefined by an arcuate length of the internal surface 70 of the casing 48between the light source 16 and the light sensors 18. In someembodiments, the clearance location 144 may be disposed at the midpointof the arcuate length between the light source 16 and the light sensors18. As the rotor blade 44 moves along the rotor path 122, the rotorblade 44 may interrupt a portion of the light 120, as shown, such thatone or more of the light sensors 18 does not detect (e.g., receive) thelight 120.

For example, prior to the rotor blade 44 moving through the clearancelocation 144, all (or a predetermined amount) of the light sensors 18may be detecting the light 120. As the rotor blade 44 moves through theclearance location 144, some of the light sensors 18 may be blocked fromreceiving the light 120. In other words, as the rotor blade 44 movesthrough the spreading light 120 from the light source 16, the rotorblade 44 casts a shadow on one or more of the light sensors 18. As therotor blade 44 continues to move through the clearance location 144 andout of the clearance location 144, all of the light sensors 18 may onceagain receive the light 120. The blade tip clearance 119 is a functionof the height of the shadow cast by the passing rotor blade 44 and/or afunction of the height of the light 120 bypassing the rotor blade 44.Accordingly, the blade tip clearance 119 may be determined based on thenumber, position, and/or identity of light sensors 18 receiving thelight 120 (i.e., successful transmissions of light 120), or the number,position, and/or identity of light sensors 18 not receiving the light120 (i.e., interruptions of light 120), as the rotor blade 44 movesthrough the clearance location 144.

Indeed, the number of the light sensors 18 detecting the light 120and/or the number of the light sensors 18 not detecting the light 120 asthe rotor blade 44 moves through the clearance location 144 may bedirectly correlated to the blade tip clearance 119 at the clearancelocation 144. For example, the smaller the blade tip clearance 119, thefewer the number of light sensors 18 that may detect the light 120 andthe greater the number of light sensors 18 that may not detect the light120. Similarly, the larger the blade tip clearance 119, the greater thenumber of light sensors 18 that may detect the light 120 and the fewerthe number of light sensors 18 that may not detect the light 120. Thelight sensors 18 may send data indicative of whether they are detectingthe light 120 to the controller 14. The controller 14 may then determinethe blade tip clearance 119 based on the data received from the lightsensors 18 (e.g., number of light sensors 18 receiving and/or notreceiving the light 120).

Alternatively, or additionally, the specific identity of the lightsensors 18 detecting the light 120 as the rotor blade 44 moves throughthe clearance location 144 may be directly correlated to the blade tipclearance 119 at the clearance location 144. For example, whenprogramming the controller 14, using other measurement techniques,mathematical calculations, computer models, etc., the blade tipclearance 119 may be calculated and stored in memory of the controller14 for each light sensor 18 receiving light 120. Thus, during lateroperation, if a particular light sensor 18 receives the light 120, thecontroller 14 can determine the corresponding blade tip clearance 119based on the identity of the particular light sensor 18 and theclearance data stored in the memory of the controller 14. If multiplelight sensors 18 receive light 120, then the controller 14 can determinethe blade tip clearance to be the maximum blade tip clearance 119associated with those light sensors 18.

Additionally, or alternatively, if multiple light sensors 18 do notreceive light 120, then the controller 14 can determine the blade tipclearance to be the minimum blade tip clearance 119 associated withthose light sensors 18. In certain embodiments, the data received fromthe light sensor 18 may provide an identity of that particular lightsensor 18 to the controller 14 based on the color or wavelength of light(e.g., by filtering the light received by the light sensor 18), anidentifier or positional data embedded in the sensor data, or some othertype of identifying information.

In the illustrated embodiment, the light sensors 18 may be stacked in adirection crosswise to the direction of the projection of the light 120(e.g., a centerline of the light 120) within the housing 86. Forexample, the light sensors 18 may be stacked along the side 195, whichmay be parallel, diverging, or converging relative to the side 193having the light source 16. The side 195 having the light sensors 18 maybe directly aligned with a radius of the casing 48 or the side 195 maybe slightly angled (e.g., 0 to 30 degrees) relative to the radius. Ineither case, the light sensors 18 may be described as being positionedat a single circumferential position (e.g., one aligned stack of sensors18 or radial stack of sensors 18) along the inner circumference 70 ofthe casing 48.

In the illustrated embodiment, the radial stack of light sensors 18 isrecessed below the top surface 100 of the sensor mount 82, such that thelight sensors 18 are disposed at a plurality of depths (e.g., radialdepths) below the top surface 100. Further, as shown, the light sensors18 and/or the light source 16 may be disposed within the inset 190 ofthe mount 82. As discussed above, the inset 190 may include thetransparent material 192. The transparent material 192 may be a solidmedium through which the light 120 may be transmitted. In someembodiments, the top surface 100 of the mount 82 may be at leastpartially defined by an upper surface of the transparent material 192,both of which may be contoured to match the curvature of the internalsurface 70 (e.g., inner circumference) of the casing 48.

FIG. 13 is a cross-sectional schematic view of an embodiment of thesensor assembly 88 having a common light source 16 and a plurality oflight sensors 18 coupled to one of the sensor mounts 82 in the casing 48of FIG. 3, illustrating a blade 44 of the rotor assembly 46 moving alongan inner circumference 70 of the casing 48 crossing at least a portionof a light path 120 (e.g., secants along the inner circumference 70)between the common light source 16 and the light sensors 18. Theillustrated embodiment of the sensor assembly 88 may be configured tomeasure the blade tip clearance 119 in substantially the same manner asdescribed above with reference to FIG. 12. However, rather than a stackof light sensors 18 as shown in FIG. 12, the illustrated embodiment ofFIG. 13 has the plurality of light sensors 18 circumferentially 42spaced apart from one another along the inner circumference 70 of thecasing 48 (i.e., multiple circumferential positions over acircumferential distance).

In some embodiments, as shown in FIG. 13, the light sensors 18 may bepositioned in the housing 86 of the mount 82, such that the lightsensors 18 are spaced in the circumferential direction 42 along the topsurface 100 of the mount 82. As discussed above in reference to FIG. 12,the blade tip clearance 119 may be determined based on the number,position, and/or identity of light sensors 18 receiving the light 120(i.e., successful transmissions of light 120), or the number, position,and/or identity of light sensors 18 not receiving the light 120 (i.e.,interruptions of light 120), as the rotor blade 44 moves through theclearance location 144. The controller 14 receives and processes thesensor data from the light sensors 18 and determines the clearance 119depending on how much light 120 is blocked and/or bypasses the rotorblade 44.

Some embodiments discussed in reference to FIGS. 12 and 13 mayincorporate one or more of the features discussed and illustrated inreference to FIG. 10. For example, in some embodiments, the sensorassembly 88 may include one or more of the auxiliary light sensors 196and/or the raised portion 194. The auxiliary light sensors 196 and theraised portion 194 may function similarly as described above. That is,the auxiliary light sensors 196 may be configured to detect the light120 as the angle of transmission of the light 120 changes due tochanging in the roundness of the casing 48. Further, as described above,the raised portion 194 of the mount 82 may be configured to block aportion of the light 120. In this manner, as the roundness of the casing48 changes, the portion of the light 120 that the raised portion 194blocks may similarly change, which may be detected by the light sensors18. In operation, the controller 14 may be configured to determine theroundness of the inner circumference 70 at least partially based on theinterruption or the transmission of light 120 relative to the raisedportion 194. Additionally, the controller 14 may be configured todetermine the roundness of the inner circumference 70 at least partiallybased on the transmission of light 120 to one or more unexpected lightsensors 18 of the plurality of light sensors 18.

FIG. 14 is a graph 220 representative of an embodiment of data obtainedfrom the sensor assembly 88 of FIGS. 12 and 13 that may be used todetermine a clearance 119 between the casing 48 and the blade 44 of therotor assembly 46. The graph 220 may include a light detection axis 222,which is indicative of the number of the light sensors 18 detecting thelight 120. The graph 220 further includes a time axis 224 indicative oftime. As discussed above, the blade tip clearance 119 may be determinedbased on the number of light sensors 18 detecting the light 120 (e.g., aminimum number) during a period of time when the rotor blade 44 passesbetween the light source 16 and the light sensors 18 (e.g., a bladesensing duration of time), wherein the number of light sensors 18detecting the light 120 decreases, reaches a local minimum 226, and thenincreases. The blade tip clearance 119 corresponds to the local minimum226 illustrated in the graph 220. At this local minimum 226, thecontroller 14 is configured to determine the blade tip clearance 119based on a correlation between the number of light sensors 18 detectinglight 120 and known blade tip clearances 119 (e.g., based on previoustesting, measurements, mathematical calculations, computer models,etc.).

As shown in FIGS. 12 and 13, the axes of the light sensors 18 may bearranged parallel with one another within the mount 82, such that thelight paths of light 120 are also parallel to one another. In someembodiments, a lateral distance or spacing between the axes of the lightsensors 18 (or the distance between the light paths of light 120) may bedependent on the construction of the light sensors 18. For example, thelight sensors 18 may be arranged in direct contact with one another tominimize the spacing between the axes of the light sensors 18 and/or thelight sensors 18 may be spaced apart from one another (e.g., with gapsbetween the sidewalls of the light sensors 18). The light sensors 18 maybe arranged in an orderly manner and/or in clusters.

FIG. 15 is a cross-sectional schematic view of an embodiment of anarrangement of the light sensors 18 of the sensor assembly 88 of FIGS.12 and/or 13, illustrating the light sensors arranged in a tightlypacked array 228 (e.g., a one-dimensional arrangement in a column or row230). In the illustrated embodiment, the opposite lateral sides 227 ofthe light sensors 18 directly abut one another without any intermediatespacing, and the light sensors 18 are arranged in a single column or row230. However, the light sensors 18 may have an intermediate spacingbetween the lateral sides 227 of the light sensors 18 and/or the lightsensors 18 may be arranged in multiple rows and columns 230, such as agrid to provide additional light sensors 18 at each radial 40 position.In a grid embodiment, the light sensors 18 may be directly aligned withone another in both rows and columns of the grid. The resolution of thesensor assembly 88 may be dependent on the spacing between the axes ofthe light sensors 18, which may also be dependent on a diameter 229 ofthe light sensors 18 and/or fiber optics inside the light sensors 18. Incertain embodiments, the diameter of each light sensor 18 (e.g., fiberoptic light sensors) may be less than or equal to approximately 3, 4, 5,6, 7, 8, 9, or 10 thousandth of an inch.

FIG. 16 is a cross-sectional schematic view of an embodiment of aplurality of light sensors 18 of the sensor assembly 88 of FIGS. 12and/or 13, illustrating the light sensors 18 arranged in a tightlypacked array 228 (e.g., a two-dimensional bundle or cluster 232). In theillustrated embodiment, the light sensors 18 are generally staggeredrelative to one another in both dimensions, e.g., in a radial direction40 and an axial direction 38. This staggered arrangement of the lightsensors 18 in the cluster 232 may improve the resolution of the sensorassembly 88 by placing the sensors 18 in intermediate positions betweenother adjacent sensors 18 (e.g., midway between the axes of sensors 18directly abutting one another) in the radial direction 40 and the axialdirection 38. Thus, the staggered arrangement of the light sensors 18 inthe radial direction 38 may significantly improve the accuracy of theblade tip clearance 119 measurements. For example, the greater theamount of staggering of the sensors 18 in the radial direction 40, thegreater the resolution of the sensor assembly 88 and thus the greaterthe accuracy of the blade tip clearance 119 measurements.

In some embodiments, the cluster 232 of the light sensors 18 may beutilized to monitor a shape of the rotor blade 44 in addition tomonitoring the blade tip clearance 119. For example, a shadow cast bythe rotor blade 44 on the light sensors 18 as the rotor blade 44 passesthrough the light 120 may form a silhouette of the rotor blade 44 in theradial and axial directions 40 and 38. Accordingly, detection of thelight 120 by the light sensors 18 may be based on the shape of theshadow of the rotor blade 44, and may output data indicative of theshape of the rotor blade 44 to the controller 14. In some embodiments,the controller 14 may utilize the data to create an image (e.g., aprofile) of the rotor blade 44. For example, the controller 14 maydisplay the image of the rotor blade 44 via an electronic display orcomputer monitor. In certain embodiments, the controller 14 may comparethe measured shape of the rotor blade 44 against a baseline shape (e.g.,an original shape) of the rotor blade 44 and identify deviations betweenthe measured shape and the baseline shape. For example, based on thecomparison between the measured and baseline shapes, the controller 14may identify areas (e.g., tip, sides, etc.) of the rotor blade 44experiencing wear, rubbing, cracking, surface defects, or otherstructural problems.

FIG. 17 is a flow chart of an embodiment of a process 238 to measure aclearance 119 between the casing 48 and the blade 44 and a roundness ofthe casing 48 of the rotor assembly 46 using the measurement system 27(e.g., the light sensors 18, the light source 16, and the controller 14)of FIGS. 12 and 13. At block 240, a diverging light (e.g., the light120) may be transmitted from a light source (e.g., the light source 16)toward a plurality of light sensors (e.g., the light sensors 18, adetector array) along a casing (e.g., the casing 48) surrounding a rotor(e.g., rotor blade 44 of the rotor assembly 46). As discussed herein,the rotor may be any suitable rotor, such as the shaft 30, or otherrotating object. Indeed, as will be appreciated, the embodimentsdiscussed herein may widely applicable for determining a clearancebetween any suitable rotor and a corresponding casing (e.g., housing).

At block 242, interruptions in the diverging light 120 may be identifiedby the light sensors 18 and the controller 14. Particularly, the lightsensors 18 may detect whether the light sensors 18 are receiving thediverging light 120 or if portions of the diverging light 120 are beinginterrupted (e.g., blocked) prior to reaching the plurality of sensors18. At block 244, a clearance 119 may be determined by the controller 14based on a number of the light sensors 18 that are not detecting thelight 120. Indeed, the greater the blade tip clearance 119, the greaterthe number of light sensors 18 that may detect the light 120. In someembodiments, the blade tip clearance 119 may be determined based onpositions of the light sensors 18 and whether or not they detect thelight 120. In other words, the blade tip clearance 119 may be directlyrelated to the positions of the light sensors 18 that are blocked fromreceiving the light 120.

At block 246, the roundness of the casing 48 may be evaluated by thecontroller 14 based on the interruptions of the light 120. As discussedabove, the roundness of the casing 48 may affect an angle oftransmission of the diverging light 120. Accordingly, the sensors 18receiving the diverging light 120 may change based on the adjusted angleof transmission of the diverging light 120. The roundness may then bedetermined by the controller 14 based on which of the sensors 18 receivethe light 120.

Further, in some embodiments, the clearance 119 and the roundness may beused to further calculate oscillations/vibrations in the rotor and/orthe casing 48. For example, at block 248, the clearance 119 of the rotorand the roundness of the casing 48 may be monitored over time.Particularly, in some embodiments, the clearance 119 between the rotorand the casing 48 may be monitored relative to one or more clearancelocations (e.g., the respective clearance locations 144) in the casing48. More specifically, a clearance 119 of a particular point on therotor may be monitored with respect to several clearance locations ofthe casing 48. Additionally, in some embodiments, multiple points (e.g.,multiple rotor blades 44) of the rotor may be monitored with respect tomultiple clearance locations of the casing 48. As will be appreciated,the clearance 119 of a particular rotor point may change overconsecutive passes through a clearance location and/or may changerelative to separate clearance locations. In other words, the rotor mayoscillate and/or vibrate relative to the casing 48 such that theclearance 119 may change over time. Similarly, in some embodiments, theroundness of the casing 48 may be monitored at multiple points along thecasing 48, which may correspond with the clearance locations discussedabove.

At block 250, a variation in the clearance 119 and the roundness overtime may be identified by the controller 14. For example, as discussedabove, instances of the clearance 119 of the rotor and the roundness ofthe casing 48 may be monitored relative to the clearance locations alongthe casing 48. Accordingly, variations (e.g., differences, trends in theclearance 119 and/or roundness) between each monitored (e.g., measured)instance of the clearance 119 and/or roundness may be monitored withrespect to time by the controller 14. At block 252, the variationidentified at block 250 may be evaluated by the controller 14 todetermine oscillations in the clearance 119 and/or roundness over theperiod of time. Particularly, variations in the clearance 119 of therotor over time may indicate that the rotor is oscillating at one ormore frequencies. Similarly, variations of the roundness of the casing48 over time may indicate that the roundness of the casing 48 isoscillating. Accordingly, in some embodiments, the frequencies of theoscillations may be determined.

At block 254, the clearance 119, the roundness, the variation, and theoscillations of the rotor and/or the casing 48 may be output to anoutput device. For example, in some embodiments, the output device maybe a computer (e.g., the controller 14) having a user interface (e.g.,an electronic display or computer monitor). Data indicative of theclearance 119, the roundness, variation, and/or oscillations may bedisplayed via the user interface. In some embodiments, the data may beportrayed in the form of graphs (e.g., clearance 119, roundness,variation, and/or oscillation with respect to time), graphicalrepresentations (e.g., 2D or 3D images) of the rotor and/or the casing48, or any other suitable manner.

At block 256, operation of the system 10 may be controlled (e.g.,adjusted) by the controller 14 based on the output of block 254. Forexample, in some embodiments, a controller (e.g., the controller 14) maycontrol operation of the compressor 20 to correct any undesirableclearances, roundness, variations, and/or oscillations of the rotorand/or the casing 48. In some embodiments, the control of the operationmay be implemented via maintenance or processing a request formaintenance for the rotor and/or the casing 48 of the compressor 20.

FIG. 18 is a schematic view of an embodiment of a measurement system 27that may be utilized to measure a clearance 260 (e.g., the blade tipclearance 119) between a rotor assembly 46 (e.g., rotor 262, blades 44,shaft 30, etc.) and a casing 48 surrounding the rotor assembly 46. Themeasurement system 27 may include one or more light sources 16, one ormore light sensors 18, and the controller 14 as described above withreference to FIGS. 5-17. The light source 16 is configured to transmitthe light 120 toward the light sensor 18. In some embodiments, the lightsource 16 may include a broadband light source 270, which is configuredto transmit broadband light (e.g., white light) toward the light sensor18. The broadband light source 270 may be configured to transmitcollimated light and/or diverging light. In some embodiments, the lightsource 16 may include a single color or wavelength light source 272. Thesingle wavelength light source 272 may be configured to directcollimated light of a single wavelength, such as of particular lightcolor, toward the light sensor 18.

The light 120 (e.g., one or more collimated lights, one or more lightbeams, a diverging light) may be transmitted from the light source 16toward the light sensor 18. At the same time, the rotor 262 (e.g., blade44) may travel along the rotor path 122 to block (e.g., interrupt) thelight 120 or a portion of the light 120. Accordingly, as discussed indetail above with reference to FIGS. 5-17, the rotor clearance 260 maybe determined by the controller 14 based on the interruption of thelight 120 by the rotor 262 (e.g., blade 44) and known information (e.g.,previous measurements) correlating the interruption of the light 120with various clearance 260 values.

The light sensor 18 is configured to detect the light 120 beingtransmitted from the light source 16. In some embodiments, the lightsensor 18 may include fiber optic sensor(s). In some embodiments, thelight sensor 18 may include one or more spectrometers 280. Thespectrometer 280 is configured to detect the light 120 and, morespecifically, may detect a color or wavelength of the light 120. In someembodiments, the light sensor 18 may include one or more optical filters282. The optical filters 282 are configured to filter the light receivedby the light sensor 18. Particularly, in some embodiments, such asembodiments including multiple light sensors 18, each light sensor 18may include a respective optical filter 282. The light 120 received bythe respective light sensors 18 may be filtered through the opticalfilter 282 to the spectrometer 280. That is, the optical filter 282 maybe configured to filter out one or more particular colors or wavelengthsof the light 120. The spectrometer 280 may then determine which of thelight sensors 18 are receiving the light 120 based on the filtered lightthat the spectrometer 280 receives.

The light sensor 18 may be communicatively coupled to the controller 14.In this way, the light sensor 18 may transmit data indicative ofdetection of the light 120. Particularly, the data may be indicative ofwhether or not the light sensor 18 is detecting the light, a color orwavelength of detected light, a duration of light detection, a positionof the light sensors, or a combination thereof. As discussed herein, thecontroller 14 may then determine the rotor clearance 260 based on thedata received from the light sensor 18 using any of the techniquesdescribed above with reference to FIGS. 5-17.

Technical effects of the present disclosure include a system and methodfor determining a clearance 119 between a rotor (e.g., blade 44) and acasing 48 surrounding the rotor. The system may include a lightmeasurement system 27 having a light source 16 configured to transmitlight 120 toward a light sensor 18. The light 120 may be transmitted asa secant relative to an arcuate surface of the casing 48. The rotor(e.g., blade 44) may rotate through the light 120 such that the light120 is interrupted from reaching the light sensor 18. The light sensor18 may output data indicative of the interruption to the controller 14.The controller 14 may then determine the clearance 119 based on thedata. In this manner, the clearance 119 may be accurately determined. Insome instances, the clearance 119 may be further utilized in controllingoperation of the compressor 20.

This written description uses examples to disclose the subject matter,including the best mode, and also to enable any person skilled in theart to practice the subject matter, including making and using anydevices or systems and performing any incorporated methods. Thepatentable scope of the subject matter is defined by the claims, and mayinclude other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal language of the claims. Thefeatures of FIGS. 1-18 may be combined in any suitable manner.

The invention claimed is:
 1. A system, comprising: a measurement system,comprising: a plurality of light sources; a plurality of light sensors;and a controller coupled to the plurality of light sources and theplurality of light sensors, wherein the controller is configured tomonitor one or more parameters between a rotor and a casing at leastpartially based on an interruption or a transmission of one or morepaths of light from the plurality of light sources to the plurality oflight sensors.
 2. The system of claim 1, wherein the one or moreparameters comprise a clearance between the rotor and the casing.
 3. Thesystem of claim 2, wherein the clearance is between a tip of a blade ofthe rotor and a curved surface of the casing.
 4. The system of claim 2,wherein the controller is configured to determine the clearance at leastpartially based on a number, a position, or an identity of theinterruptions or the transmissions of paths of light from the pluralityof light sources to the plurality of light sensors.
 5. The system ofclaim 2, wherein the controller is configured to determine the clearanceat least partially based on a minimum number of the transmissions ofpaths of light from the plurality of light sources to the plurality oflight sensors when a portion of the rotor passes between the pluralityof light sources and the plurality of light sensors.
 6. The system ofclaim 2, wherein the controller is configured to determine the clearanceat least partially based on an identity and a position of theinterruptions and the transmissions of paths of light from the pluralityof light sources to the plurality of light sensors when a portion of therotor passes between the plurality of light sources and the plurality oflight sensors.
 7. The system of claim 6, wherein the controller isconfigured to determine the identity of the transmissions of paths oflight based on different colors or wavelengths of the light.
 8. Thesystem of claim 7, wherein the measurement system is configured totransmit the different colors or wavelengths of the light from theplurality of light sources.
 9. The system of claim 7, wherein themeasurement system is configured to filter the light received by theplurality of light sensors to obtain the different colors or wavelengthsof the light.
 10. The system of claim 1, wherein the one or moreparameters comprise a roundness of a circumference.
 11. The system ofclaim 10, wherein the roundness of the circumference corresponds to aninner circumference of the casing.
 12. The system of claim 10, whereinthe measurement system comprises a raised portion disposed between theplurality of light sources and the plurality of light sensors, and thecontroller is configured to determine the roundness of the circumferenceat least partially based on the interruption or the transmission of oneor more paths of light relative to the raised portion.
 13. The system ofclaim 10, wherein the controller is configured to determine theroundness of the circumference at least partially based on an unexpectedtransmission of one or more paths of light to one or more light sensorsof the plurality of light sensors.
 14. The system of claim 1, whereineach of the plurality of light sources is configured to transmit thelight along a path of light to one of the plurality of light sensors asa secant across a curved surface.
 15. The system of claim 14, whereinthe paths of light between the plurality of light sources and theplurality of light sensors are substantially parallel to one another.16. The system of claim 14, wherein the paths of light between theplurality of light sources and the plurality of light sensors areradially spaced from the curved surface at a plurality of radialheights, and the plurality of radial heights is stored in memory of thecontroller.
 17. The system of claim 1, wherein the measurement systemcomprises a sensor mount having a top surface, wherein the plurality oflight sources and the plurality of light sensors are coupled to thesensor mount, wherein the plurality of light sources arecircumferentially spaced apart from the plurality of light sensorsrelative to an axis of rotation of the rotor, each of the plurality oflight sources is configured to transmit light along a path of light toone of the plurality of light sensors, the paths of light are spacedfrom the top surface at a plurality of radial heights, and the sensormount is configured to mount in a circumferential groove along a curvedsurface of the casing.
 18. The system of claim 1, comprising a machinehaving the rotor and the casing, wherein the measurement system iscoupled to the machine, and the machine comprises a compressor, aturbine, or a combination thereof.
 19. A system, comprising: ameasurement system, comprising: a sensor mount having a top surface; aplurality of light sources coupled to the sensor mount; and a pluralityof light sensors coupled to the sensor mount, wherein the plurality oflight sources are circumferentially spaced apart from the plurality oflight sensors, each of the plurality of light sources is configured totransmit light along a path of light to one of the plurality of lightsensors, and the paths of light are spaced from the top surface at aplurality of radial heights.
 20. A method, comprising: transmittinglight from a plurality of light sources toward a plurality of lightsensors along a plurality of paths of light positioned at a plurality ofradial heights relative to a curved surface along a rotational pathbetween a rotor and a casing; and monitoring one or more parametersbetween the rotor and the casing at least partially based on aninterruption or a transmission of one or more of the plurality of pathsof light.